MODEL FM4 (HANDWHEEL OPERATED) SERVICE AND …

1 BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT FM4 ( handwheel OPERATED) SERVICE AND OPERATION MANUALPROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 2 MODEL FM4 SERVICE AND OPERATION MANUALINTRODUCTIONIn appreciation to our customer for purchasing our product, we have prepared this OperationManual to assist you in the Operation, Maintenance, Assembly and Installation of the ValveworksUSA API 6A MODEL FM4 Gate Valve. We encourage following the recommendations in this bookletto attain the best possible SERVICE from our product, which is designed and proven to offer theservice one can expect of a quality contact a representative for more specific information pertaining to a special problem:1650 SWAN LAKE ROADBOSSIER CITY, LA USA 71111 PHONE318-425-0266 FAX318-425-0934 TOLL USA management and employees are committed to continually improve the effectiveness of our quality management system to produce a quality assured product which meets or exceeds our customer s expectations and must be taken as to the surrounding area and its potential dangers of kills!

2 Even a loose, stand alone valve may contain trapped pressure which will turn any component into a projectile missile when disassembled, causing injury or death. Never stand over a component or in its path of release during assembly. Always operate the valves from the open to close position slowly releasing trapped pressure. Always remove fittings first, taking extreme caution to their potential danger as a projectile. If the valve is frozen and can not be operated , take extreme caution to the disassembly of the components. Caution should be taken when handling components during disassembly and assembly, as most components are heavy, greasy, hard to handle and have edges which can cause injury. Always be cautious of how the valve is positioned and standing. Be sure the valve is secured in position so there is no possible chance of tipping over. Never apply test pressure above the manufacturers rated working pressure.

3 The shell test pressure above the working pressure has already been tested by the manufacturer and is not required after the initial assembly test of the valve. The manufacturer has already verified the quality of the valve shell body components and will void the warranty from the manufacturer if the valve is pressure tested above the rated working pressure indicated for the valve. Always wear steel toes shoes, hard hat, eye and ear protection while performing BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 3 MODEL FM4 SERVICE AND OPERATION MANUALTABLE OF CONTENTSAPPLICATIONS4 TEMPERATURE RATING4 TRIM CHART4 ORDERING INFORMATION5 OPERATION5 ASSEMBLY DRAWING6,8 BILL OF MATERIALS7,9 DIS-ASSEMBLING THE VALVE11-12 DIS-ASSEMBLING THE BONNET SUB-ASSEMBLY13-14 PERIODIC MAINTENANCE14-15 INSTALLING INJECTION PACKING16 PROCEDURE TO VENT OR DRAIN17 TROUBLESHOOTING18 MAINTENANCE INTERVALS18 TEST PROCEDURE19 HYDROSTATIC BODY TEST20 HYDROSTATIC SEAT TEST21 VISUAL INSPECTION22 FIELD HOOK-UP BOOKLET OF VALVEWORKS USA.

4 DO NOT REPRODUCE WITHOUT EXPLICIT 4 MODEL FM4 SERVICE AND OPERATION MANUALAPPLICATIONSV alveworks USA FM4 gate valve unit can be applied to the following sizes and working AVAILABLEGATE VALVE SIZE5-1/8 , 7-1/16 MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP)2M, 3M, 5 MTEMPERATURE RANGE-60 C TO 121 C(-75 F TO 250 F)TEMPERATURE RATINGTEMPERATURECLASSIFICATIONOPERATING RANGE C( F)K-6082-75180L-4682-50180N-4660-50140P- 2982-20180S-18600140T-18820180U-18121025 0V212135250 TRIM CHARTMATERIALCLASSMINIMUM MATERIAL REQUIREMENTSBODY, BONNET, END AND OUTLETCONNECTIONSPRESSURE-CONTROLLING PARTS, STEMS, AND MANDREL HANGERSAA - General ServiceCarbon or low-alloy steelCarbon or low-alloy steelBB - General ServiceCarbon or low-alloy steelStainless steelCC - General ServiceStainless steelStainless steelDD - Sour SERVICE aCarbon or low-alloy steel bCarbon or low-alloy steel bEE - Sour SERVICE aCarbon or low-alloy steel bStainless steel bFF - Sour SERVICE aStainless steel bStainless steel bHH - Sour SERVICE aCRAs bCRAs ba As defined by NACE In compliance with NACE shown by API-6A.

5 For specific details consult Valveworks BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 5 MODEL FM4 SERVICE AND OPERATION MANUALORDERING INFORMATIONThe following information should be provided with any request for quote or order placement of Valveworks USA FM4 Gate valves : MODEL of Valve Size of Valve Pressure Rating (maximum) API 6A Requirements (PR-PSL) API 14D Requirements (Class of SERVICE ) Temperature Rating (API 6A) Material (API 6A) Any Special Test Requirements Any Special Material Requirements Any Special Coating or Protection Requirements Other Specifications and/or CertificationsOPERATIONV alveworks USA MODEL FM-4 Expanding Gate and FM-4 Slab Gate valves are generally hand wheel operated . The expanding gate of the MODEL FM-4 Valve consists of two pieces (major and minor) acting one against the other by means of a dual wedge expanding when the valve is either fully closed or fully opened. The expansion effect of the wedge against the seats, through the parallel faces of the gate, provides a strong and positive seal against pulsations and vibrations created by flow MODEL FM-4 slab gate valve is a one piece slab gate that uses two floating seats to generate a highly reliable seal.

6 The slab gate eliminates the chance of trapping pressure within the body cavity which can cause pressure Fully open the valve before installing or shipping. The sealing area of the gates, in the full open position, is protected by the body and is less likely to be Do not remove the molybdenum disulfide coating from internal parts. This coating serves as a lubricantand corrosion To hydrostatically test the valve body to full API test pressure, the valve must be in a partially open position. When testing the valve in the closed position (seat test), do not exceed the working pressure stamped on the valve identification During storage always leave the valve in fully opened or fully closed position. This will tightly wedge the gate and segment against the seats and prevent damage to the sealing area of both the gate and seats. 5. When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate.

7 6. The valve should be fully closed or fully opened during lubrication of the body or seats. 7. Seat lubrication pressures should not exceed the maximum allowable API test pressure. The expanding gate design of our MODEL FM4 valves provides a tight mechanical positive seal; however to properly effect this seal, the valve must be fully opened or fully closed in order to wedge the gate and segment against the seats. Do not back off the hand This method of operation will prevent damage to the sealing surfaces of the gate and seats, and will increase the life of the valve. BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 6 MODEL FM4 SERVICE AND OPERATION MANUALMODEL FM4 - EXPANDING GATE7-1/16 3M (HANDWHEEL operated ) BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 7 MODEL FM4 - BILL OF MATERIALSITEMDESCRIPTIONQTY1 UPPER BONNET12 LOWER BONNET13 GATE ASSEMBLY14 GATE GUIDE25 STUD W/ NUT326 PACKING RETAINER BUSHING17 BONNET SEAL RING, UPPER18 BONNET SEAL RING, LOWER19 BEARING HOUSING110 STEM111 ALEMITE FITTING112 PACKING INJECTION FITTING113 BODY GREASE FITTING214 PACKING115 BEARINGS216 HANDWHEEL117O-RING118 handwheel NUT119 BODY120 SEAT221O-RING2 MODEL FM4 SERVICE AND OPERATION BOOKLET OF VALVEWORKS USA.

8 DO NOT REPRODUCE WITHOUT EXPLICIT 8 MODEL FM4 SERVICE AND OPERATION MANUALMODEL FM4 - SLAB GATE7-1/16 3M (HANDWHEEL operated ) BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 9 MODEL FM4 - BILL OF MATERIALSITEMDESCRIPTIONQTY1 UPPER BONNET12 LOWER BONNET13 GATE, SLAB14 LIFT NUT15 GATE GUIDE26 STUD W/ NUT327 PACKING RETAINER BUSHING18 BONNET SEAL RING, UPPER19 BONNET SEAL RING, LOWER110 BEARING HOUSING111 STEM112 ALEMITE FITTING113 PACKING INJECTION FITTING114 BODY GREASE FITTING215 PACKING116 BEARINGS217 HANDWHEEL118O-RING119 handwheel NUT120 BODY121 SEAT222O-RING2 MODEL FM4 SERVICE AND OPERATION BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 10 MODEL FM4 SERVICE AND OPERATION manual X MATERIAL TYPE Y COATING141300 NONE; PHOSPHATE, MOLY, STANDARD PAINT/COATING, POWDER COAT1A41401B10401C10181D10201 ESA285-C1 NITRIDE QPQ-PHOSPHATE; EXCEPTION - FC BODY BUSHING - DO NOT NITRIDE1F10262410SS FORGED2AS424003174SS3 ANITRONIC 502 HARDFACE-STELLITE #6 SPRAY & FUSE4316SS4A316/304SS4B304SS3 HARDFACE - TUNGSTEN CARBIDE5 BRONZE6 INCONEL 7186 AINCONEL 7254 HARDFACE - COLMONOY #56 BINCONEL X7507 MONEL5 ELECTROLIS NICKEL8A487-4D8AA487-4C6 WELD ON HARDFACE8 BCA158 CCF8M7 ZINC PLATE8 DCF3M8 XYLAN COATING8 ECA6NM9(4130) INCONEL 625 CLAD9 STELLITE #69 APLASTIC9A(4130)SS-316-RING GROOVE9 BSTELLITE #3 The last two digits in the part number vary with X Material Type and Y Coating.

9 The table below gives the different available material types and coatings. Please refer to the valve tag to know the material type and coating on the valve BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 11 MODEL FM4 SERVICE AND OPERATION MANUALDISASSEMBLING THE BODY2. Unscrew and remove the handwheel nut using a crescent (Vertical Orientation)Operate the valve to check for trapped Remove the Unscrew and remove all Bonnet Bolts using an impact Release the packing pressure from the injection fitting using pressure relief tool PN Remove the Packing Injection BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 12 MODEL FM4 SERVICE AND OPERATION MANUAL7. Replace the handwheel and rotate it in the counter-clockwise direction. This will separate the Gate from the Stem. 8. Remove the Bonnet Sub-Assembly10. Remove the Gate Remove the Remove the Remove the Bonnet Seal Ring and Grease BOOKLET OF VALVEWORKS USA.

10 DO NOT REPRODUCE WITHOUT EXPLICIT 13 MODEL FM4 SERVICE AND OPERATION MANUALDISASSEMBLING THE BONNET SUB-ASSEMBLY1. Unscrew and remove Bearing Housing with a strap Remove the Stem. One of the Thrust Bearings will also be Remove the other Thrust Remove the Packing Retainer Remove the Stem Packing and Packing Injection Sleeve with a pick. Avoid scratching the internal wall of the Bonnet during BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT 14 MODEL FM4 SERVICE AND OPERATION MANUALPERIODIC MAINTENANCEThe MODEL FM4 gate valves are non-lubricated sealed valves , in that they do not require the injection of lubricants or sealants to effectively seal. However, to prevent corrosion, excessive wear and ensure continued operation, a routine maintenence program is recommended to extend the life and serviceability of the TOOLSTo perform normal maintenance and lubrication, the following tools are recommended:Grease pump with adapter and couplingSafety pressure releasing toolSTEM BEARING LUBRICATIONV alveworks USA API valves are equipped with alemite hydraulic type 1/8 NPT bonnet grease fittings.